U.S. patent application number 10/965538 was filed with the patent office on 2005-04-21 for drainage place for exterior wall product.
This patent application is currently assigned to Progressive Foam Technologies, Inc.. Invention is credited to Culpepper, Patrick M., Wilson, Richard C..
Application Number | 20050081468 10/965538 |
Document ID | / |
Family ID | 34435151 |
Filed Date | 2005-04-21 |
United States Patent
Application |
20050081468 |
Kind Code |
A1 |
Wilson, Richard C. ; et
al. |
April 21, 2005 |
Drainage place for exterior wall product
Abstract
An apparatus and method for a drainage system of an exterior
wall of a building comprising insulation having a rear face for
contact with the exterior wall of the building and a drainage plane
positioned on the rear face for removal of water from the exterior
wall.
Inventors: |
Wilson, Richard C.;
(Traverse City, MI) ; Culpepper, Patrick M.;
(Massillon, OH) |
Correspondence
Address: |
WILLIAM M HANLON, JR
YOUNG & BASILE, PC
3001 WEST BIG BEAVER ROAD
SUITE 624
TROY
MI
48084-3107
US
|
Assignee: |
Progressive Foam Technologies,
Inc.
Beach City
OH
44608
|
Family ID: |
34435151 |
Appl. No.: |
10/965538 |
Filed: |
October 14, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60511527 |
Oct 15, 2003 |
|
|
|
Current U.S.
Class: |
52/528 |
Current CPC
Class: |
E04F 13/007 20130101;
E04F 13/0846 20130101; E04F 13/0864 20130101; E04F 13/0876
20130101; E04F 13/0892 20130101; E04B 1/76 20130101 |
Class at
Publication: |
052/528 |
International
Class: |
E04D 013/00; E04D
001/00 |
Claims
What is claimed is:
1. A siding panel for mounting on an exterior wall of a building
comprising: a panel backing including a rear face mountable on the
exterior wall, the rear face including a plurality of grooves
operable to remove water from a surface of the exterior wall; and a
siding component mountable on the panel backing.
2. The siding panel of claim 1, wherein the panel backing further
comprises a foam panel backing.
3. The siding panel of claim 2, wherein the plurality of grooves
further comprise a plurality of grooves integrally formed into the
rear face of the foam panel backing.
4. The siding panel of claim 2, wherein the plurality of grooves
further comprise a plurality of grooves cut into the rear face of
the foam panel backing.
5. The siding panel of claim 4, wherein the plurality of grooves
further comprise a plurality of grooves cut into the rear face of
the foam panel backing using hot wires.
6. The siding panel of claim 2, wherein the foam panel backing
further comprises a contoured foam panel backing having a front
face contoured complementary to a rear face of the siding
component.
7. The siding panel of claim 1, wherein the plurality of grooves
further comprise: a plurality of drainage grooves formed on the
rear face; and a plurality of exit grooves positioned on a pocket
formed proximate to a bottom edge of the rear face so that the exit
grooves intersect the drainage grooves for facilitating the removal
of water from the surface of the exterior wall.
8. The siding panel of claim 7, wherein the plurality of drainage
grooves further comprise a network of grooves positioned in a
diamond shaped grid pattern.
9. The siding panel of claim 7, wherein the plurality of drainage
grooves further comprise a network of parallel grooves oriented in
a diagonal pattern.
10. The siding panel of claim 7, wherein the plurality of drainage
grooves further comprise a network of parallel grooves oriented in
a vertical pattern.
11. The siding panel of claim 7, wherein the plurality of drainage
grooves further comprise a network of grooves positioned in a
square grid pattern oriented at an angle of forty-five degrees
(45.degree.) from vertical.
12. The siding panel of claim 1, wherein the plurality of grooves
further comprise each groove having a tapered bottom for increased
water flow due to reduced surface tension.
13. The siding panel of claim 1, wherein the plurality of grooves
further comprise each groove having a rounded bottom for increased
water flow due to reduced surface tension.
14. The siding panel of claim 1, wherein the plurality of grooves
further comprise each groove having a tapered edge to encourage
water to flow freely into the groove.
15. The siding panel of claim 1, wherein the siding component
further comprises a plurality of apertures to channel water from
the plurality of grooves of the panel backing to an exterior
surface of the siding.
16. The siding panel of claim 12, wherein the plurality of
apertures further comprise a plurality of weep holes.
17. The siding panel of claim 1, wherein the siding component
further comprises a nail strip including a plurality of nail
apertures for securing the siding to the exterior wall of the
building.
18. The siding panel of claim 1, wherein the siding component
further comprises: a locking lip located proximate to a top edge of
the siding panel; a locking flange located proximate to a bottom
edge of the siding panel and configured to operably engage the
locking lip of an adjacent siding panel.
19. In an insulation backing for use with siding products, the
insulation backing having a rear face, the improvement comprising:
a plurality of drainage grooves located in the rear face; and at
least one exit groove located in the rear face, the at least one
exit groove forming a path for the flow of water from the plurality
of drainage grooves to an area external of the rear face of the
insulation backing when the insulation backing is in a mounted
position.
20. The improvement according to claim 19, wherein the insulation
backing further comprises a contoured foam backing.
21. The improvement according to claim 19, further comprising: a
siding component adhesively fixed to the insulation backing and
forming a composite siding panel.
22. The improvement according to claim 21, wherein the siding
component further comprises a plurality of apertures forming a path
for the flow of water from the plurality of drainage grooves to an
exterior surface of the siding component.
23. The improvement according to claim 21, wherein the insulation
backing further comprises a foam backing having a front face
contoured to a shape of the siding component.
24. A method for making a siding panel for mounting on an exterior
wall of a building comprising the steps of: forming a panel backing
having a flat rear face mountable on the exterior wall, the rear
face including a plurality of grooves operable to remove water from
a surface of the exterior wall; and mounting a siding component on
the panel backing.
25. The method of claim 24, wherein the step of forming the
plurality of grooves further comprises molding the plurality of
grooves into the rear face.
26. The method of claim 24, wherein the step of forming the
plurality of grooves further comprises cutting the plurality of
grooves into the rear face.
27. The method of claim 26, wherein the step of cutting the
plurality of grooves into the rear face further comprises cutting
the plurality of grooves into the rear face using a plurality of
hot wires.
28. The method of claim 24, wherein the step of mounting the siding
component further comprises forming a siding component.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional patent
application Ser. No. 60/511,527 filed on Oct. 15, 2003, which is
incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a siding panel for an
exterior wall of a building. In particular, the invention provides
for a drainage plane positioned on the rear face of a contoured
foam backer used with siding products. The drainage plane allows
water to more efficiently dissipate from the exterior wall.
BACKGROUND OF THE INVENTION
[0003] The construction industry, both new construction and
remodeling, is increasingly confronted with problems associated
with the buildup of moisture on surfaces within exterior walls.
This moisture buildup may cause various types of mold, including
black mold. Such mold is frequently blamed for causing serious
respiratory illnesses and numerous other health conditions in both
humans and animals. Individuals often go to great expense to remove
mold from their homes, and in extreme cases walls and even entire
structures are torn down.
[0004] Building codes have long required that exterior walls be
permeable so that moisture can escape if such moisture finds its
way into the wall. However, on occasion due to poor insulation,
inadequate flashing, leaking pipes or bad building practices, water
can nonetheless find its way into exterior walls. In some cases
water can be found in such large quantities that it overwhelms the
exterior wall system. In other words, the exterior wall material
simply cannot dissipate the moisture fast enough before conditions
become sufficient to promote the growth of mold.
[0005] A need has arisen to improve dissipation of water in the
exterior walls of buildings.
SUMMARY OF THE INVENTION
[0006] The present invention is intended to augment exterior wall
systems to assist in the removal of water or water vapor from such
exterior walls. Exterior walls often include insulation products,
for example, contoured foam backing or composite siding. Exterior
insulation includes a rear face that contacts the building. The
present invention provides a drainage plane on that rear face to
facilitate the removal of water from the exterior wall. The
drainage plane can be made up of a grid of grooves that provide a
path for water to flow. These grooves encourage water from leaks
and water from heavy condensation to run theredown off the exterior
wall and away from the building. In the preferred embodiment, and
when used with composite siding, the water flows out through weep
holes located in the bottom of the siding. It is understood that
the grooves may be positioned in any number of ways, including
vertically or diagonally.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The description herein makes reference to the accompanying
drawings wherein like reference numerals refer to like parts
throughout the several views, and wherein:
[0008] FIG. 1 is a front perspective view of a composite siding
panel including the drainage plane of the present invention;
[0009] FIG. 2 is a rear exploded perspective view of a panel
backing and siding product including the drainage plane of the
present invention;
[0010] FIG. 3A is a rear plan view of the backing of FIG. 2;
[0011] FIG. 3B is a rear plan view of the backing showing the
drainage plane arranged in a diagonal pattern;
[0012] FIG. 3C is a rear plan view of the backing showing the
drainage plane arranged in a vertical pattern;
[0013] FIG. 3D is a rear plan view of the backing showing the
drainage plane arranged in a square pattern; and
[0014] FIG. 4 is a cross sectional view illustrating a preferred
groove profile.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] The present invention relates to a drainage arrangement
positioned on a rear face of an exterior insulation product. The
construction market utilizes a large number of exterior insulation
products. The preferred embodiment of the instant application is
described in the context of composite siding by example only. It is
understood that the instant invention could be applied to any
exterior insulation product having a planar surface.
[0016] The drainage arrangement, as it is positioned on the
otherwise flat rear face of a foam backer, is generally referred to
as a drainage plane. The drainage plane is configured to encourage
water from leaks and water from heavy condensation to run down
grooves positioned therein. The grooves can be of any of a wide
variety of configurations and can be laid out in any of a wide
variety of patterns. The grooves can be positioned in a grid and
can be positioned anywhere from vertically to some angle off the
vertical. The drainage plane of the present invention is
particularly beneficial in those cases where a foam board is
positioned flat against another component such as an OSB panel that
would naturally resist the water from freely running down the back
of the OSB panel.
[0017] With reference to the drawings wherein like items are
numbered alike, and with particular reference to FIGS. 1, 2, and
3A, a composite siding product 10 is illustrated. The composite
siding product 10 can include a panel backing 14 that can be
operably attachable or mountable to a siding component 12. By way
of example and not limitation, the siding component 12 can be a
contoured siding product 12 and/or the panel backing 14 can be a
contoured foam backer. It is understood that the backing 14 can be
attached to the siding component 12 in a wide variety of fashions,
where attaching and mounting are general terms that can include, by
way of example and not limitation, an adhesive, chemical bonding,
interlocking complementary surfaces, fasteners, and/or "dropping
in" the backing 14 at the job site. As seen in FIG. 4, the rear
face of the backing 14 can be positioned parallel to and proximate
to an exterior wall 18 of a building. Returning to FIGS. 1, 2, and
3A, the siding component 12 can include a nail strip 15 that can
include at least one nail aperture 15', a locking flange 17, and/or
a locking lip 17'. The locking flange 17 can be located at a top
edge of the siding 12 and the locking lip 17' can be located at a
bottom edge of the siding component 12. The locking flange 17 can
be configured to operably engage the locking lip 17' of an adjacent
contour siding 12. In this way, the composite siding panels 10 can
be vertically interlocked in courses up the exterior wall 18 of the
building. Installers can drive nails through nail apertures 15' to
secure each piece onto the exterior wall 18.
[0018] By way of example and not limitation, the backing 14 can be
formed of an expanded polystyrene (EPS) foam material, and the
siding component 12 can be formed of a vinyl material. By way of
example and not limitation, the foam can have a permeability rating
of 1.0 or higher. By way of example and not limitation, a suitable
adhesively-formed composite siding panel on which the present
invention may be advantageously used is manufactured by Progressive
Foam Technologies of Beach City, Ohio.
[0019] With reference to FIG. 2, the composite siding product 10 is
further illustrated. As illustrated in FIG. 2, the rear face of the
backing 14 can include a drainage plane made up of a grid network
that can include a plurality of drainage grooves 19. As shown in
the example of FIG. 2, the drainage grooves 19 can be positioned in
a diamond pattern and can be set apart with a spacing of one inch.
As water flows through the grid made up of the drainage grooves 19,
the water can flow into a plurality of exit grooves 20. The exit
grooves 20 can be positioned on a pocketed area 21 of the backing
14. The exit grooves 20 can intersect the drainage grooves 19. The
exit grooves 20 can facilitate the water to travel into at least
one weep hole 13. After exiting the at least one weep hole 13, the
water can be harmlessly directed to the exterior surface of the
siding component 12 and ultimately to the ground.
[0020] As illustrated in FIG. 3A, each set of drainage grooves 19
can be arranged in a diamond pattern at roughly a 30.degree. angle
from a vertical orientation. It is understood, that, as will be
described below, the grooves can be positioned in a wide variety of
angles and in a wide variety of patterns.
[0021] With reference to FIGS. 3B-3D, there is illustrated a
plurality of examples of grid arrangements. These arrangements can
include a diagonal pattern as illustrated in FIG. 3B, a vertical
pattern as illustrated in FIG. 3C, and/or and a square pattern with
the drainage grooves 19 positioned at an angle of 45.degree. from
the vertical orientation as illustrated in FIG. 3D.
[0022] With reference to FIG. 4, the preferred profile of each
drainage groove 19 and each exit groove 20 is illustrated. By way
of example and not limitation, each drainage groove 19 and each
exit groove 20 can have a depth of approximately {fraction (1/16)}
to 1/8 of an inch, inclusive. In the preferred embodiment, each
drainage groove 19 and exit groove 20 can have a tapered or rounded
bottom 23 to cause the water to flow with reduced surface tension.
Each drainage groove 19 and each exit groove 20 can include a
tapered edge 21 to encourage water to flow freely into each groove.
As water is drawn into the grid, a syphoning effect will cause
water flow to increase.
[0023] The drainage plane of the present invention may be formed in
a wide variety of ways. By way of example and not limitation, the
drainage plane can be formed by molding the drainage grooves 19 and
the exit grooves 20 into the rear face of the backing 14, and/or
the drainage grooves 19, and the exit grooves 20 can be cut into
the rear face of the backing 14 using hot wires or the like.
* * * * *